Separator for a fuel cell including a first separator plate regulating an assembly position of a second separator plate

ABSTRACT

A fuel cell separator includes a first separator plate and a second separator plate for an anode or a cathode. The first and second separator plates are adjacent to each other for assembly in a fuel cell stack. A first protrusion is formed at an edge portion of the first separator plate and protrudes toward the second separator plate arranged facing the first separator plate. A second protrusion is formed at an edge portion of the second separator plate and protrudes toward the first separator plate arranged facing the second separator plate. With the first and second separator plates adjacent to each other, since side surfaces of the first and second protrusions push each other, assembly positions of the first and second separator plates are regulated. The first and second protrusions are arranged such that opposing side surfaces thereof are spaced from each other. A third gasket is arranged in a gap between the first and second protrusions.

CROSS REFERENCE TO RELATED APPLICATION

This application is a division of U.S. patent application Ser. No.15/636,769 entitled “SEPARATOR FOR A FUEL CELL”, filed Jun. 29, 2017,which claims priority to and the benefit of Korean Patent ApplicationNo. 10-2016-0171603 filed in the Korean Intellectual Property Office onDec. 15, 2016. The entire contents of these prior filed applications areincorporated herein by reference.

BACKGROUND Technical Field

The present disclosure relates to fuel cells, and more particularly to aseparator for a fuel cell.

Background Art

A polymer electrolyte membrane fuel cell (PEMFC, hereinafter, simplyreferred to as a fuel cell) stack includes a plurality of unit cellsthat are stacked on each other. Each unit cell includes a membraneelectrolyte assembly (MEA), gas diffusion layers, separators, andgaskets. Simplification and unification of components of a fuel cellstack are required to save costs, facilitate assembling of a stack, andimprove productivity.

A conventional fuel cell stack features a structure in which first-typeseparator plates are each provided with a gasket on one side thereof andare produced through single-side injection molding, and in whichsecond-type separator plates are each provided with gaskets on bothsides thereof and are produced through double-side injection molding.The first-type separator plates and second-type separator plates arealternately stacked on each other. The conventional technology has adrawback that a conventional separator is thick so as not to be deformedwhen undergoing double-side injection molding. Moreover, when unifyinganode and cathode separators, spot welding is performed in four cornersof the anode and cathode separators. During this process, misalignmentof the separators may occur and assembly defects may be generated.

The foregoing is intended merely to aid in the understanding of thebackground of the present disclosure. The foregoing is not intended tomean that the present disclosure falls within the purview of the relatedart that is already known to those skilled in the art.

SUMMARY

Accordingly, the present disclosure is provided, keeping in mind theabove problems occurring in the prior art. An object of the presentdisclosure is to provide a separator for a fuel cell, the separatorsolving a problem of a conventional separator. In a conventionalseparator, two kinds of separators having different thicknesses are useddue to double-side gasket molding. This reduces misalignment when a pairof separators is stacked and assembled with each other and increasesproduction efficiency by enabling self-alignment.

In order to accomplish the above object, the present disclosure providesa separator for a fuel cell. The separator includes a first separatorplate and a second separator plate for an anode or a cathode, the firstseparator plate and the second separator plate being adjacent to eachother for assembly in a fuel cell stack. The separator also includes afirst protrusion formed at an edge portion of the first separator plateand protruding toward the second separator plate arranged facing thefirst separator plate. The separator further includes a secondprotrusion formed at an edge portion of the second separator plate andprotruding toward the first separator plate arranged facing the secondseparator plate. With the first separator plate and the second separatorplate adjacent to each other, since side surfaces of the firstprotrusion and the second protrusion push each other, assembly positionsof the first separator plate and the second separator plate areregulated.

The second protrusion may be arranged inside or inward of the firstprotrusion and thus may be nearer a center of a fuel cell than the firstprotrusion.

The separator may further include a first gasket combined with a surfaceof the first separator plate, the surface of the first separator platenot facing the second separator plate, at a position corresponding tothe first protrusion. The separator may also include a second gasketcombined with a surface of the second separator plate, the surface ofthe second separator plate not facing the first separator plate, at aposition corresponding to the second protrusion.

In the separator, a highest end of the first protrusion may support thesecond separator plate and a highest end of the second protrusion maysupport the first separator plate.

In the separator, a highest end of the first protrusion may be fixed tothe second separator plate and a highest end of the second protrusionmay be fixed to the first separator plate.

The highest ends of the first protrusion and the second protrusion mayhave a flat surface and the flat surfaces may support the secondseparator plate and the first separator plate.

The first protrusion and the second protrusion may have a first cavityand a second cavity, respectively. A first gasket and a second gasketmay be formed to fill the first cavity and the second cavity,respectively.

In the separator, each of the first gasket and the second gasket mayinclude a base in contact with a surface of the corresponding firstseparator plate and second separator plate, respectively, a fillingportion inserted in the corresponding first cavity and second cavity,respectively, and a main protrusion formed protruding in an oppositedirection of the filling portion.

In the separator, an auxiliary protrusion may be formed on the base ofthe first gasket or the second gasket, may be positioned next to themain protrusion, and may protrude in the same direction as the mainprotrusion.

The auxiliary protrusion of the first gasket may be formed at a positioncorresponding to the second protrusion of the second separator plate andthe auxiliary protrusion of the second gasket may be formed at aposition corresponding to the first protrusion of the first separatorplate.

The main protrusion and the auxiliary protrusion may have the sameheight.

The first protrusion and the second protrusion may be arranged such thatopposing side surfaces of the first protrusion and the second protrusionare in contact with each other.

The first protrusion and the second protrusion may be arranged such thatopposing side surfaces of the first protrusion and the second protrusionare spaced from each other. A third gasket may be arranged in a gapbetween the first protrusion and the second protrusion.

The third gasket may support the opposing side surfaces of the firstprotrusion and the second protrusion in a sideways direction.

The first protrusion and the second protrusion may be provided with afirst cavity and a second cavity, respectively. The first cavity and thesecond cavity may be filled with the first gasket and the second gasket,respectively. Opposing side walls of the first protrusion and the secondprotrusion may be provided with respective through holes. The firstgasket and the second gasket in the first cavity and the second cavitymay be connected to each other via the through holes.

In the separator, cooling water may flow between the first separatorplate and the second separator plate.

The separator for a fuel cell according to the present disclosure solvesa conventional problem that two kinds of separator plates havingdifferent thicknesses are used due to double-side gasket injectionmolding, reduces misalignment during stacking and unifying a pair ofseparator plates, and improves production efficiency by adopting aself-aligning structure.

The present disclosure has advantages described below. First, sinceseparator plates with the same thickness are used for a separator for afuel cell, the number of manufacturing processes and costs are reduced.Second, since the thickness of the separator plates is reduced, the sizeand weight of a fuel cell stack can be decreased. Third, since theseparator for a fuel cell has a self-aligning structure, assembly of theseparator for a fuel cell is facilitated and alignment between anode andcathode separators is improved. This results in an improvement inquality and production efficiency (reduction in manufacturing defects)of a separator for a fuel cell.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagram illustrating an unassembled state of a separator fora fuel cell according to one embodiment of the present disclosure;

FIG. 2 is a diagram illustrating an assembled state of a separator for afuel cell according to a first embodiment of the present disclosure;

FIG. 3 is a diagram illustrating an assembled state of a separator for afuel cell according to a second embodiment of the present disclosure;and

FIG. 4 is a diagram illustrating an assembled state of a separator for afuel cell according to a third embodiment of the present disclosure.

DETAILED DESCRIPTION

FIG. 1 is a diagram illustrating an unassembled state of a separator fora fuel cell according to one embodiment of the present disclosure. FIG.2 is a diagram illustrating an assembled state of a separator for a fuelcell according to a first embodiment of the present disclosure. FIG. 3is a diagram illustrating an assembled state of a separator for a fuelcell according to a second embodiment of the present disclosure. FIG. 4is a diagram illustrating an assembled state of a separator for a fuelcell according to a third embodiment of the present disclosure.

According to the present disclosure, a separator for a fuel cellincludes a first separator plate 100 and a second separator plate 200for an anode or a cathode. The plates are adjacent to each other when afuel cell stack is assembled. A first protrusion 120 is formed at anedge portion of the first separator plate 100 and protrudes toward thesecond separator plate 200. A second protrusion 220 is formed at an edgeportion of the second separator plate 200 and protrudes toward the firstseparator plate 100. When the first separator plate 100 and the secondseparator plate 200 are combined with each other, opposing side surfacesof the first protrusion 120 and the second protrusion 220 are in tightcontact with each other, which naturally regulates the assembledpositions of the first separator plate 100 and the second separatorplate 200 in a lateral direction.

FIG. 1 shows an unassembled state of a separator for a fuel cellaccording to one embodiment of the present disclosure. The separator fora fuel cell roughly includes the first separator plate 100 and thesecond separator plate 200. Each separator plate 100 or 200 is providedwith a manifold. The separator plates are combined with a reactive layerM that is a combined structure of a Membrane Electrolyte Assembly (MEA)and a Gas Diffusion Layer (GDL).

As illustrated in FIG. 1, in a separator for a fuel cell including ananode and a cathode, each separator plate is provided with a protrusion.The separator plates are self-aligning due to the protrusions that areengaged to be next to each other in a lateral direction.

As to the first separator plate 100 and the second separator plate 200for an anode or a cathode, the first protrusion 120 is formed at an edgeportion of the first separator plate 100 and protrudes toward the secondseparator plate 200. The second protrusion 220 is formed at an edgeportion of the second separator plate 200 and protrudes toward the firstseparator plate 100. The second protrusion 220 is arranged to be closerto the center of a fuel cell than inside the first protrusion 120. Inother words, the second protrusion 220 is arranged inside or furtherinward of the first protrusion 120 relative to the center of the fuelcell.

FIG. 2 is a cross-sectional view of an assembled state of a separatorfor a fuel cell according to a first embodiment of the presentdisclosure. Opposing side surfaces of the first protrusion 120 and thesecond protrusion 220 can be in contact with each other. With referenceto FIG. 1, the first protrusion 120 and the second protrusion 220 havean overall rectangular frame shape. The second protrusion 220 isarranged inside the first protrusion 120 when a separator for a fuelcell is assembled. The opposing side surfaces of the first protrusion120 and the second protrusion 220 are in contact with each other,thereby supporting each other in a sideways direction. In other words,the assembled positions of the first separator plate 100 and the secondseparator plate 200 are regulated in a press-fit connection manner.Therefore, when assembled, the first separator plate 100 and the secondseparator plate 200 are self-aligned with each other. Cooling water canflow between the first separator plate 100 and the second separatorplate 200. The first protrusion 120 and the second protrusion 220function to seal the cooling water by use of a mutually supportingstructure so that the water does not leak.

Specifically, a highest end of the first protrusion 120 supports thesecond separator plate 200 and a highest end of the second protrusion220 supports the first separator plate 100. This structure regulatesboth lateral and vertical positions of the first separator plate 100 andthe second separator plate 200. The highest end of the first protrusion120 is fixed to the second separator plate 200 and the highest end ofthe second protrusion 220 is fixed to the first separator plate 100, forexample, through welding or bonding. Specifically, the first separatorplate 100 and the second separator plate 200 are first positioned not tobe displaced at an initial assembly stage. Then the first separatorplate 100 and the second separator plate 200 are securely fixed througha proper process, such as by for example, welding. In addition, thehighest ends of the first protrusion 120 and the second protrusion 220have a flat surface. Therefore, the first separator plate 100 and thesecond separator plate 200 can be supported on the flat surfaces. Inother words, due to the flat surfaces of the highest ends, the firstseparator plate 100 and the second separator plate 200 can be stablysupported.

As shown in FIG. 2, the separator for a fuel cell further includes afirst gasket 140 combined with a surface of the first separator plate100 at a position corresponding to the first protrusion 120. The surfaceof the first separator plate is not facing the second separator plate200. The separator also includes a second gasket 240 combined with asurface of the second separator plate 200 at a position corresponding tothe second protrusion 220. The surface of the second separator plate isnot facing the first separator plate 100.

FIG. 2 is a cross-sectional view of the assembled state of the separatorfor a fuel cell according to the first embodiment of the presentdisclosure. Specifically, the first protrusion 120 and the secondprotrusion 220 have a first cavity and a second cavity, respectively.The first gasket 140 and the second gasket 240 may be formed in thefirst cavity and the second cavity, respectively. Therefore, with theuse of only the protrusions, it is possible to regulate assembledpositions of the separator plates and to stably maintain secure sealing.Since the first gasket 140 and the second gasket 240 are filled ordisposed in the first cavity and the second cavity, respectively,positions of each component part are securely maintained.

The first gasket 140 or the second gasket 240 includes a base B incontact with the surface of the corresponding separator plate, a fillingportion B1 inserted in the corresponding cavity, and a main protrusionB2 that protrudes from the surface of the filling portion B1 in theopposite direction of the filling portion B1. The first gasket 140 orthe second gasket 240 may further include an auxiliary protrusion B3that is arranged next to the main protrusion B2 and that protrudes fromthe base B in the same direction as the main protrusion B2. The positionof the main protrusion B2 is maintained due to the filling portion B1,and the main protrusion B2 provides perfect sealing in combination withthe auxiliary protrusion B3. The base B, the filling portion B1, themain protrusion B2, and the auxiliary protrusion B3 are made of the samematerial and are integrally formed through injection molding that isperformed in a state in which the separator plate is inserted in themold.

Specifically, the auxiliary protrusion B3 of the first gasket 140 may beformed at a position corresponding to the second protrusion 220 of thesecond separator plate 200. Likewise, the auxiliary protrusion B3 of thesecond gasket 240 may be formed at a position corresponding to the firstprotrusion 120 of the first separator plate 100. The auxiliaryprotrusion B3 forms a double-sealing structure in combination with themain protrusion B2 and provides an upward supporting function incombination with the main protrusion B2, thereby forming a dynamicallystrong supporting structure in a fuel cell. In addition, since theheights of the main protrusion B2 and the auxiliary protrusion B3 arethe same as each other, a uniform compression load is applied to themain protrusion B2 and the auxiliary protrusion B3 in a verticaldirection. Therefore, the main protrusion B2 and the auxiliaryprotrusion B3 are load balanced, which prevents concentration of stress,thereby ensuring high durability of a sealing structure of a fuel cell.

FIG. 3 is a cross-sectional view illustrating an assembled state of aseparator for a fuel cell according to a second embodiment of thepresent disclosure. Opposing side surfaces of the first protrusion 120and the second protrusion 220 are spaced from each other. A third gasketB5 is arranged in a gap within the spacing between the first protrusion120 and the second protrusion 220. The third gasket B5 pushes the sidesurfaces of the first protrusion 120 and the second protrusion 220 in asideways direction. In this embodiment, an O-ring gasket is insertedbetween cooling surfaces of the first and second protrusions 120, 220 ofthe first and second separator plates 100, 200, thereby increasingstrength and sealing performance of a separator for a fuel cell. Inaddition, since a slight positioning error (tolerance) usually occurs inpositioning during assembly, the third gasket B5 functions to absorb andeliminate the positioning error.

FIG. 4 is a cross-sectional view illustrating an assembled state of aseparator for a fuel cell according to a third embodiment of the presentdisclosure. The first protrusion 120 and the second protrusion 220 areprovided with a first cavity and a second cavity, respectively. Thefirst cavity and the second cavity are filled with the first gasket 140and the second gasket 240, respectively. Opposing side walls of thefirst protrusion 120 and the second protrusion 220 are provided withrespective through holes 142 and 242 at positions corresponding to eachother. The first gasket 140 and the second gasket 240 in the firstcavity and the second cavity are connected to each other by a connectionstrip B′ extending through the through holes 142 and 242. In thisembodiment, the protrusions 120, 220 of the separator plates 100, 200are provided with a piercing hole. A gasket material is charged into thecavities of the protrusions so that the gaskets 140, 240 can be formedin the cavities. According to this embodiment, it is possible to improvestrength and sealing performance of a stack structure. Due to thisstructure, although eccentric force is applied, since the first gasket140 and the second gasket 240 are pulling each other, sealingperformance is not deteriorated.

The separator for a fuel cell according to the present disclosure cansolve a problem of a conventional separator for a fuel cell in which twokinds of separator plates having different thicknesses are used due todouble-side injection molding. In addition, the separator according tothe present disclosure can reduce misalignment of separator plates whenthe separator plates are stacked and assembled. Further, the separatoraccording to the present disclosure increases production efficiency byusing a self-aligning structure.

The present disclosure has the following advantages. With the use ofseparator plates having the same thickness, the number of manufacturingprocesses and the cost of a separator for a fuel cell can be reduced.With the use of separator plates having a reduced thickness, a fuel cellstack with a reduced size and weight can be provided. Due to theself-alignment structure, assembly of a separator for a fuel cell isfacilitated. Due to precise alignment between anode or cathode separatorplates, quality and production efficiency (reduction of manufacturingdefects) of a separator for a fuel cell are improved.

Although preferred embodiments of the present disclosure have beendescribed for illustrative purposes, those having ordinary skill in theart will appreciate that various modifications, additions andsubstitutions are possible, without departing from the scope and spiritof the disclosure as set forth in the accompanying claims.

What is claimed is:
 1. A separator for a fuel cell, the separator comprising: a first separator plate and a second separator plate for an anode or a cathode, the first separator plate and the second separator plate being adjacent to each other for assembly in a fuel cell stack; a first protrusion formed at an edge portion of the first separator plate and protruding toward the second separator plate arranged facing the first separator plate; a second protrusion formed at an edge portion of the second separator plate and protruding toward the first separator plate arranged facing the second separator plate; a first gasket combined with a surface of the first separator plate, the surface of the first separator plate not facing the second separator plate, at a formation position of the first protrusion; and a second gasket combined with a surface of the second separator plate, the surface of the second separator plate not facing the first separator plate, at a formation position of the second protrusion, wherein, with the first separator plate and the second separator plate adjacent to each other, since side surfaces of the first protrusion and the second protrusion push each other, assembly positions of the first separator plate and the second separator plate are regulated, wherein the first protrusion and the second protrusion are arranged such that the side surfaces of the first protrusion and the second protrusion are spaced from each other, wherein a third gasket is arranged in a gap between the first protrusion and the second protrusion, wherein each of the first gasket and the second gasket includes a base in contact with the surface of each of the first separator plate and the second separator plate, wherein a filling portion of the first gasket is inserted in a first cavity of the first protrusion and a filling portion of the second gasket is inserted in a second cavity of the second protrusion, and wherein each of the first gasket and the second gasket includes a main protrusion formed protruding in an opposite direction of the filling portion of the first gasket and the second gasket, respectively.
 2. The separator according to claim 1, wherein the second protrusion is arranged inward of the first protrusion and thus is nearer a center of the fuel cell than the first protrusion.
 3. The separator according to claim 1, wherein a top end of the first protrusion supports the second separator plate, and a top end of the second protrusion supports the first separator plate.
 4. The separator according to claim 1, wherein a top end of the first protrusion is fixed to the second separator plate, and a top end of the second protrusion is fixed to the first separator plate.
 5. The separator according to claim 1, wherein top ends of the first protrusion and the second protrusion each have a flat surface, and wherein the flat surfaces support the second separator plate and the first separator plate, respectively.
 6. The separator according to claim 1, wherein the first gasket and the second gasket are formed to fill the first cavity and the second cavity, respectively.
 7. The separator according to claim 1, wherein the third gasket supports the side surfaces of the first protrusion and the second protrusion in a sideways direction.
 8. The separator according to claim 7, wherein an upper surface or a lower surface of the third gasket contact with at least one of the first separator plate and the second separator plate.
 9. The separator according to claim 1, wherein an auxiliary protrusion is formed on the base of the first gasket or the second gasket, is positioned next to the main protrusion, and protrudes in the same direction as the main protrusion.
 10. The separator according to claim 9, wherein the auxiliary protrusion of the first gasket is formed at a stack position, which is the same as the second protrusion of the second separator plate in a stack direction of the first separator plate and the second separator plate, and wherein the auxiliary protrusion of the second gasket is formed at a stack position, which is the same as the first protrusion of the first separator plate in the stack direction.
 11. The separator according to claim 9, wherein the main protrusion and the auxiliary protrusion have the same height. 